Case Study: Sheybarah Hotel, Red Sea Development

Design & Build Structures / Facades

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Hotel & Residential

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Mild Steel / Stainless Steel

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Ongoing

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KSA
  • Location Sheybarah, KSA
  • Client TRSDC
  • Design Architect Killa Design
  • Engineer Arcadis
  • Main Contractor Grankraft Industries LLC
  • Status In Progress - Scheduled to open in 2023

The Sheybarah Hotel is a hyper luxury resort on Sheybarah Island on the Red Sea archipelago, designed by Killa Design in Dubai. It comprises a series of overwater and inland villas located on the uninhabited Sheybarah Island, 30-minutes by boat from the mainland. The island is home to a highly diverse environment with mangroves, sandy beach, and some of the most beautiful coral reefs in the world.

Each overwater villa is lifted above the water surface, thus reducing the ground foundation impact to a minimum and offers panoramic views to the sea, with sliding doors that open to a deck, a seating area, and an infinity pool with uninterrupted views of the sea and the horizon.

The approach to the façade design has been to minimise visual impact with each villa having polished stainless-steel cladding that reflects the water, the sky, and the reef with the rich sea life below. This material is the key feature of the project and is used in various locations such as the lobby, dining areas, spa, and beach villas.

Original concept for mirrored stainless steel

Original concept for main structure: 95 Tons

Design & CGI by Killa Design

 

Grankraft’s Involvement

Having previously successfully collaborated with Killa Design on the Museum of the Future in Dubai, Grankraft was approached during the main contract tender stage to resolve the detailing of the various mirrored stainless steel façades of this project.

The project’s geometry, particularly dealing with the complexity of the shape and the jointing, required every detail to be modeled, analyzed, and optimised in advance of fabrication. Through an extensive sample and mock-up process, Grankraft managed the removal of the hairline joints between the panels, achieving a seamless undistorted mirror stainless steel surface as per the design intent.

By involving Grankraft in early stages of the design, the client was also able to see the mock-up villa pod in person and gain confidence with the immaculate fabrication of the design. Grankraft was approached by the Client with the scheme design package prepared by the consultants and was appointed a Design & Build contract.

 

Design Engineering

Towards Skeleton Stability

  1. To capture exact wind tunnel forces and apply to our structural model. Input DATA constitutes 12 load cases with 9108 FE load points
  2. To capture exact wave pressures and apply to our structural model. Input DATA constitutes 7 load cases with 315000 load points.
  3. Control points for both the tests are different.
  4. Natural frequency for the proposed design was 1.79 hertz resulting in a time period of 0.55 s. Grankraft needs to advise the improvement methods which could probably increase the Natural frequency to 2 Hertz or more.
  5. To limit floor accelerations to 0.007 m/s2 with critical damping zetta 1 % as per ISO 10137 standards.
  6. Deflection limits L/500.
  7. To calibrate wind induced reactions between Grankraft model to interpretive report tables.
  8. To calibrate wave induced reactions between Grankraft model to interpretive report tables.

Grankraft’s design engineering workflow

Towards Stainless Steel Shell Performance

  1. Excessive shell buckling when subjected to 75 degrees Celsius. (FE Model)
  2. Significant local stresses observed in connections. (FE Model)
  3. While forming the shell, residual stress observed was beyond limits. Plastic deformation observed on the surface.

Grankraft’s design engineering workflow

Grankraft’s design engineering workflow

Residual stress during forming process

  • Residual stress based on UK fracture mechanic assessment procedure BS7102 in conjunction with BS7910 stress relaxation rule could be attained and lower of the values to be used for valuation.
  • Equation1 Qm = Yield Strength
  • Equation2 Qm = (1.4 – stress ref/stress f ) x yield strength
  • Stainless steel yield strength = 205 N/mm2
  • Stainless steel Ultimate strength = 400 N/mm2
  • Permitted Qm = (1.4 – 100/205) x 205 = 187 N/mm2

 

 

Temperature analysis of shell surface and developments at stages

Surface temperature = 70 degrees Celsius

 

Initial proposal, type 1 FX,FY,FZ translations locked

572 N/mm2 local stress is observed at the bolt location due to extreme temperature gradient. Unsafe material is expected to yield.

2nd proposal, type 2 FX & FY translation locked

 

 

0.068 N/mm2 local stress is observed at the bolt location due to extreme temperature gradient. This was achieved because of the in-plane movement permitted at the joint. Due to the swivel loose movement, we felt it may end up with a potential noise issue when the structure breaths in and out during temperature differentials.

 

3rd proposal, type 3 FX & FY translation locked

EPDM bimetallic separators are used for passive vibration isolation and to control noise.

0.0765 N/mm2 local stress is observed at the bolt location due to extreme temperature gradient. We have proposed our detail for the consultants’ approval.

 

Construction

For the Sheybarah Hotel, Grankraft has developed a logistic plan in which the capsules will be prefabricated in Grankraft’s facilities in Dubai and will be shipped by sea to the final installation location.

Fabricating the villa pod off-site in our factory increases the quality due to the controlled factory environment. It enables achieving integrated, optimised solutions and coordination of all disciplines, further enhanced through the use of BIM to achieve good design coordination and clash detection between all trades at an early design stage, minimising the potential number of on-site changes as an outcome of the construction sequencing analysis.

Furthermore, the fabrication in our factory not only reduces the cost and time due to higher efficiencies, but also improves health and safety during construction.

 

1st visual mock-up with type 2 fittings

size of mock-up H = 6m r = 9m

 

  • Subjected to an atmospheric temperature variation between 45 to 50 degrees Celsius.
  • No visible distortions or ripples noticed.
  • Strain near the supports measured was approx. 0.0006. Hence the stress computed is approx. 133 N/mm2 against 205 N/mm2 permitted.

Latest Visual mock-up

size of mock-up H = 4   r = 5.5 m

 

A full new production unit has been created in our factory to accommodate the needs of this project and to ensure the maximum quality and accuracy is achieved for the stainless steel shell. The stainless steel panels are first received in our facilities once the production drawings have been coordinated with all trades.

The panels, which at this stage are oversized, are stretched, and bent into shape using a custom-made set of molds created for each specific panel curvature. Once the panels have the required curvature, they are cut into the exact dimensions required. Following this, the edges of the panels are reworked in order to be prepared for the welding operations as part of the pre-assembly. Lastly, the panels are polished to achieve a perfect mirror finish, first using automatic machines and then by hand. To successfully perform these activities, we have developed our own machinery kits which don’t exist on the market.

Once the pre-assembled panels are protected and ready to leave the factory, they are transported to our assembly yard, where the panels are installed to the primary structure using a bespoke mechanical fixation detail which provides thermal and acoustic separation between the façade panels and the structural frame, also allowing for the designed movement depending on the lengths and directions of the panels. After a further control of the geometry, the pre-assembled panels are then welded together, and the final polishing is done.

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